Laminate web comprising an apertured layer and method for manufacture thereof

ABSTRACT

A laminate web comprising a first web, a second web joined to the first web at a plurality of discrete bond sites; and a third material disposed between at least a portion of the first and second nonwovens. The third material is apertured in regions adjacent the bond sites, such that the first and second nonwoven webs are joined through the apertures. In one embodiment an apertured laminate web is disclosed, having a first extensible web having a first elongation to break, and a second extensible web joined to the first extensible web at a plurality of bond sites, the second extensible web having elongation to break. A third web material is disposed between the first and second nonwovens, the third web material having a third elongation to break which is less than both of the first or second elongations to break. In a further embodiment, an apertured laminate web is disclosed, having first and second extensible webs being joined at a plurality of discrete bond sites and a third material disposed between the first and second nonwoven webs. The first and second nonwoven webs are in fluid communication via the apertures and have distinct regions being differentiated by at least one property selected from the group consisting of basis weight, fiber orientation, thickness, and density.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation-in-part application of U.S.Ser. No. 09/584,676, filed on May 31, 2000 in the names of Curro et al.,which is a continuation-in-part of U.S. Serial No. 09/467,938, filed onDec. 21, 1999 in the names of Curro et al.

FIELD OF THE INVENTION

[0002] This invention relates to a multilayer laminate web, and moreparticularly to a laminate web wherein at least a central layer isapertured. In some embodiments the entire multilayer laminate web isapertured.

BACKGROUND OF THE INVENTION

[0003] Laminate webs formed by the joining of discrete webs in a layeredrelationship are well known in the art. For example, often laminatenonwoven webs are utilized in disposable absorbent articles such asdiapers and adult incontinence products. Such laminated webs can be usedas a topsheet, backsheet, or side panels. One example of a laminate webis a film/nonwoven laminate useful for a stretch side panel of adisposable diaper. Nonwoven/nonwoven laminates are also utilized toprovide additional bulk or softness to a web component. Likewise,film/film laminate webs can provide benefits by combining thecharacteristics of various films in a layered relationship. Laminatewebs can also be called composite webs.

[0004] Less common examples of laminate webs include laminates ofdissimilar materials. The-materials may be dissimilar in mechanicaltensile properties, thermal properties, or visual/tactile properties.For example, a nonwoven web may be joined to a relatively stiff fabricto provide for a soft surface feel to the fabric. The dissimilarmaterials may be joined by melt bonding, adhesive bonding, ultrasonicbonding, and the like. Bonding methods are often determined by thematerials themselves, but often require adhesive bonding. For example, alaminate or composite of materials having widely differing meltproperties may require an adhesive layer between laminate layers. Evenmaterials having similar melt properties, such as nonwoven andthermoplastic film materials are often joined by adhesive for adequatebonding to prevent unwanted delamination. Although adhesive may benecessary, such processing methods can be expensive due to the additionof adhesive, and the resulting laminate is often relatively stiff,depending on the laminate materials and the level of adhesive added.

[0005] Often laminate webs are intended to combine properties of theconstituent layers to achieve synergistic benefits. For example,EP-B-715,571 issued to Wadsworth discloses a multilayered nonwovencomposite web intended for use as a substitute for a woven web such as atextile web. The web comprises at least a layer of thermoplasticman-made fibers and a layer of cellulose-based fibers. Thecellulose-based fiber layer is disclosed as thermally bonded to thethermoplastic man-made fiber layers at spaced apart locations. However,it appears that thermal bonding between both, or all, the layers isnecessary to produce the requisite bonding.

[0006] EP-A-112,654 issued to Haq, et al. discloses a laminatecomprising two sheets of nonwoven fabric or the like having sandwichedbetween them a solid core material which may be a highly porous,optionally liquid-containing, polymer. The two outer sheets are bondedto each other, without involving the core material, by means of aplurality of small, spaced bonding points, for example, spot-welds.Preferably the core material is in continuous sheet form and isperforated to accommodate the bonding points. However, it appears itwould present a significant processing problem to register theperforations of the core material in order to have the outer layersbonded therethrough.

[0007] For many purposes it is desirable to have an apertured nonwovenweb, the apertured web being characterized by a plurality of openings,or perforations, in the web. Such apertures can provide for an open meshappearance, as well as beneficial texture and cloth-like properties.Such apertured nonwoven webs can be made by methods known in the art.For example, EP-B-164,740 issued to Shimalla discloses an aperturednon-woven fabric comprising a web of thermoplastic fibers is described.The fabric is formed with a multiplicity of fused patterned regions andadjacent substantially non-fused regions, there being apertures formedwithin a plurality of the fused patterned regions but not within theadjacent regions. The fabric is produced by heat embossing a non-wovenweb of thermoplastic fibers at a temperature above the softening pointof the fibers whereby the regions of the web compressed by theprojections of the embossing means become fused, and immediatelythereafter drafting the embossed web so that apertures are formed in thefused patterned regions. However, it is not apparent that the methoddisclosed would produce a laminate of nonwoven webs, or a laminate ofdissimilar materials.

[0008] Another beneficial method of aperturing a nonwoven web, includinglaminates of nonwoven webs is disclosed in EP-A-852,483, issued toBenson et al. Disclosed is a laminate material having, for example, atleast one layer of a spunbonded web joined to at least one layer of ameltblown web, a bonded carded web, or other suitable material. Suchapertured webs are useful as the topsheet in a disposable absorbentarticle. However, this disclosure does not teach laminating webscomprising dissimilar materials (e.g., materials of different materialclasses or having differing material properties).

[0009] A perforated multilayer elastic coversheet comprising anintermediate elastic layer between upper and lower nonwoven layers isdisclosed in EP-A-784,461 issued to Palumbo. The upper and lower layersare connected to the intermediate layer only around the perimeters ofthe perforations. While providing an apertured, elastic laminate, it isnot apparent that the method disclosed could produce laminatescomprising thermally-dissimilar materials.

[0010] As mentioned, nonwoven webs are beneficial as components ofdisposable consumer products, such as diapers, incontinence briefs,training pants, feminine hygiene garments, and the like, as well as inwipes such as disposable wet wipesHowever, used alone, such nonwovensare limited in the range of beneficial properties, including visual,tactile, strength or absorbent properties due to the limits of knownmethods of making, particularly as compared to woven or knittedmaterials. Importantly, laminates of nonwoven webs and other materialsfor use in disposable consumer products have heretofore been limited dueto processing limitations, including incompatible materials (e.g.,thermally dissimilar materials), cost considerations (e.g., adhesivelamination costs) or tactile properties (e.g., softness and visualaesthetics).

[0011] Nonwovens are also beneficial components of other consumerproducts, such as non-absorbent disposable garments, durable garments,automotive components, upholstered furniture, filtration media, andother consumer or commercial goods. Nonwovens used in these and otherapplications benefit from their wide range of visual and tactileproperties. However, in many cases, the nonwovens used could benefitfrom being combined with other dissimilar materials in a composite web.

[0012] Accordingly, it would be desirable to have laminate webs ofdissimilar material properties which are not dependent upon thermalcompatibility of each constituent layer for structural integrity.

[0013] Additionally, it would desirable to have a laminate webcomprising nonwoven webs and component webs of different materialproperties.

[0014] Additionally, it would be desirable to have a laminate web formedby joining the constituent layers without adhesive.

[0015] Further, it would be desirable to have an apertured laminate webhaving visually distinct regions giving a fabric-like or knit-like lookand feel.

BRIEF SUMMARY OF THE INVENTION

[0016] A laminate web is disclosed, the laminate web comprising a firstweb, a second web joined to the first web at a plurality of discretebond sites; and a third material disposed between at least a portion ofthe first and second nonwovens. The third material is apertured inregions adjacent the bond sites, such that the first and second nonwovenwebs are joined through the apertures.

[0017] In one embodiment an apertured laminate web is disclosed, havinga first extensible web having a first elongation to break, and a secondextensible web joined to the first extensible web at a plurality of bondsites, the second extensible web having a second elongation to break Athird web material is disposed between the first and second nonwovens,the third web material having a third elongation to break which is lessthan both of the first or second elongations to break.

[0018] In a further embodiment, an apertured laminate web is disclose,having first and second extensible webs being joined at a plurality ofdiscrete bond sites and a third material disposed between the first andsecond nonwoven webs. The first and second nonwoven webs are in fluidcommunication via the apertures and have distinct regions beingdifferentiated by at least one property selected from the groupconsisting of basis weight, fiber orientation, thickness, and density.

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] While the specification concludes with claims pointing out anddistinctly claiming the present invention, it is believed the same willbe better understood by the following drawings taken in conjunction withthe accompanying specification wherein like components are given thesame reference number.

[0020]FIG. 1 is a perspective of one embodiment of a laminate web of thepresent invention.

[0021]FIG. 2 is a cross-sectional view of a portion of the laminate webshown in FIG. 1.

[0022]FIG. 3 is a magnified detail view of one bond site of a laminateweb of the present invention.

[0023]FIG. 4 is a top plan view of another embodiment of the laminateweb of the present invention.

[0024]FIG. 5 is a cross-sectional view of a portion of the laminate webshown in FIG. 4.

[0025]FIG. 6 is a top plan view of another embodiment of the laminateweb of the present invention.

[0026]FIG. 7 is a cross-sectional view of a portion of the laminate webshown in FIG. 6.

[0027]FIG. 8 is a photomicrograph of one embodiment of a laminate web ofthe present invention.

[0028]FIG. 9 is a schematic representation of a process for making alaminate web of the present invention.

[0029]FIG. 10 is a perspective view of a melt bond calendaringapparatus.

[0030]FIG. 11 is a schematic representation of a pattern for theprotuberances of the calendaring roll.

[0031]FIG. 12 is a perspective view of an apparatus for stretching alaminate of the present invention to form apertures therein.

[0032]FIG. 13 is a cross-sectional view of a portion of the matingportions of the apparatus shown in FIG. 12.

[0033]FIG. 14 is a perspective view of an alternative apparatus forstretching a laminate of the present invention in the cross-machinedirection to form apertures therein.

[0034]FIG. 15 is a perspective view of another alternative apparatus forstretching a laminate of the present invention in the machine directionto form apertures therein.

[0035]FIG. 16 is a perspective representation of an apparatus forstretching a laminate of the present invention in both the cross-machineand machine directions to form apertures therein.

[0036]FIG. 17 is a perspective view of a disposable absorbent articlehaving components that can be made of laminate web material of thepresent invention.

[0037]FIG. 18 A-B are cross-sectional photographs of a bond site beforeand after the tensioning step to form an aperture.

DETAILED DESCRIPTION OF THE INVENTION

[0038] As used herein, the term “absorbent article” refers to deviceswhich absorb and contain body exudates, and, more specifically, refersto devices which are placed against or in proximity to the body of thewearer to absorb and contain the various exudates discharged from thebody. The term “disposable” is used herein to describe absorbentarticles which are not intended to be laundered or otherwise restored orreused as an absorbent article (i.e., they are intended to be discardedafter a single use and, preferably, to be recycled, composted orotherwise disposed of in an environmentally compatible manner). A“unitary” absorbent article refers to absorbent articles which areformed of separate parts united together to form a coordinated entity sothat they do not require separate manipulative parts like a separateholder and liner.

[0039] As used herein, the term “nonwoven web” is used in its plainmeaning as understood in the art and refers to a web that has astructure of individual fibers or threads which are interlaid, but notin any regular, repeating manner. Nonwoven webs have been, in the past,formed by a variety of processes, such as, for example, meltblowingprocesses, spunbonding processes and bonded carded web processes.

[0040] As used herein, the term “microfibers”, refers to small diameterfibers having an average diameter not greater than about 100 microns.

[0041] As used herein, the term “meltblown fibers”, refers to fibersformed by extruding a molten thermoplastic material through a pluralityof fine, usually circular, die capillaries as molten threads orfilaments into a high velocity gas (e.g., air) stream which attenuatesthe filaments of molten thermoplastic material to reduce their diameter,which may be to a microfiber diameter. Thereafter, the meltblown fibersare carried by the high velocity gas stream and are deposited on acollecting surface to form a web of randomly dispersed meltblown fibers.

[0042] As used herein, the term “spunbonded fibers”, refers to smalldiameter fibers which are formed by extruding a molten thermoplasticmaterial as filaments from a plurality of fine, usually circular,capillaries of a spinneret with the diameter of the extruded filamentsthen being rapidly reduced by drawing.

[0043] As used herein, the term “unitary web” refers to a layered webcomprising two or more webs of material, including nonwoven webs, thatare sufficiently joined, such as by thermal bonding means, to behandled, processed, or otherwise utilized, as a single web.

[0044] As used herein, “laminate” and “composite” when used to describewebs of the present invention, are synonymous. Both refer to a webstructure comprising at least two webs joined in a face to facerelationship to form a multiple-layer unitary web.

[0045] As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as, for example, block,graft, random and alternating copolymers, terpolymers, etc., and blendsand modifications thereof. Furthermore, unless otherwise specificallylimited, the term “polymer” shall include all possible geometricalconfigurations of the material. These configurations include, but arenot limited to, isotactic, syndiaotactic and random symmetries.

[0046] As used herein, the term “elastic” refers to any material which,upon application of a biasing force, is stretchable, that is,elongatable, at least about 60 percent (i.e., to a stretched, biasedlength, which is at least about 160 percent of its relaxed unbiasedlength), and which, will recover at least 55 percent of its elongationupon release of the stretching, elongation force. A hypothetical examplewould be a one (1) inch sample of a material which is elongatable to atleast 1.60 inches, and which, upon being elongated to 1.60 inches andreleased, will recover to a length of not more than 1.27 inches.

[0047] Many elastic materials may be elongated by more than 60 percent(i.e., much more than 160 percent of their relaxed length), for example,elongated 100 percent or more, and many of these materials will recoverto substantially their initial relaxed length, for example, to within105 percent of their initial relaxed length, upon release of the stretchforce. Such materials are denoted herein by the term “highly elastic”which refers to any material which upon application of a biasing force,is stretchable, that is, elongatable, at least about 200 percent (i.e.,to a stretched, biased length, which is at least about 300 percent ofits relaxed unbiased length), and which, will to within 105 percent oftheir initial relaxed length, upon release of the stretch force.Therefore, highly elastic materials are generally also elastic, but notall elastic materials are highly elastic.

[0048] As used herein, the term “nonelastic” refers to any materialwhich does not fall within the definition of “elastic” above.

[0049] As used herein, the term “extensible” refers to any materialwhich, upon application of a biasing force, is elongatable, at leastabout 25 percent without experiencing catastrophic failure. Catastrophicfailure includes substantial tearing, fracturing, rupturing, or otherfailure in tension such that, if tested in a standard tensile tester,the failure would result in a sudden significant reduction in tensileforce. As used herein, the term “highly extensible” refers to anymaterial which, upon application of a biasing force, is elongatable, atleast about 100 percent without experiencing catastrophic failure.

[0050] The Laminate Web

[0051] The laminate web 10 of the present invention comprises at leastthree layers or plies, disposed in a layered, face-to-face relationship,as shown in FIG. 1. The layers should be sufficiently thin to beprocessible as described herein, but no actual thickness (i.e., caliper)is considered limiting. A first outer layer 20, is preferably thermallybondable, and is preferably a nonwoven web comprising a sufficientquantity of thermoplastic material, the web having a predeterminedextensibility and elongation to break. By “sufficient quantity” is meanta quantity of thermoplastic material adequate to enable enough thermalbonding upon application of heat and/or pressure to produce a unitaryweb. A second outer layer, 40, is preferably the same material as firstouter layer 20, but may be a different material, also being thermallybondable and having a predetermined extensibility and elongation tobreak. At least one third central layer 30 is disposed between the twoouter layers. The laminate web 10 is processed by joining means, such asby ultrasonic welding, or thermal calendaring as described below toprovide a plurality of melt bond sites 50 that serve to couple the outerlayers 20 and 40, and, in some embodiments, portions of central layer30, thereby forming the constituent layers into a unitary web. Whenjoined together, the two outer layers form an interior region betweenthem. The interior region is the space between the outer layerssurrounding the bond sites 50. In a preferred embodiment, the thirdcentral layer 30 substantially fills the interior region, the thirdcentral layer 30 being apertured coincident the bond sites 50.

[0052] While the laminate web 10 is disclosed primarily in the contextof nonwoven webs and composites, in principle the laminate web 10 can bemade out of any web materials that meet the requirements, (e.g., meltproperties, extensibility) as disclosed herein. For example, the outerlayers 20 and 40 can be thermoplastic films, micro-porous films,apertured films, and the like. Central layer 30 can be paper, includingtissue paper; metal, including metal foil; other non-thermoplastic webmaterial, woven fabric, and the like. In general, it is required thatouter layer materials be flexible enough to be processed as describedherein. However, central layer can be a brittle, relatively stiffmaterial, as long at it also can be processed as described herein,albeit possibly becoming fractured, broken, or otherwise broken up inthe process. One of the unexpected advantages of the present invention,therefore, is the discovery that novel web properties can be exhibitedby the choice of central layer 30 disposed between the two outer layers.

[0053] Non-apertured Embodiment

[0054] In one embodiment, as shown in cross-section in FIG. 2, centrallayer 30 can be apertured, without aperturing the two outer layers toprovide a three-layer laminate characterized by the laminate web 10 (asa whole) being un-apertured, while the central layer 30 is apertured.Importantly, the web of the present invention can be made by the methodof the present invention without requiring registration of the layers toensure bonding of the outer layers through the apertures of the centrallayer(s). One way of describing a preferred embodiment of a web 10 asdescribed above, is that the unitary web 10, when viewed orthogonally bythe un-aided human eye from a distance of approximately 50 cm, exhibitsno apertures or perforations through the entire laminate, but bond sites50 are nevertheless visible.

[0055] The laminate web 10 is further characterized in that the joiningof the three plies into a unitary web can be achieved in the absence ofadhesive. That is, in certain preferred embodiments no adhesive isrequired to bond the plies together; joining is achieved by the input ofenergy into the constituent layers, such as by thermal melt bonding ofthe two outer layers together at the melt bond sites 50. In otherembodiments, the energy input can be via ultrasonic bonding.Accordingly, a significant benefit of the present invention is theprovision of a laminate web, that is a unitary web, formed without theuse of adhesives. Not only does this simplify processing and lower thecost of the laminate web, when certain materials such as nonwoven websare used, it results in a more flexible, softer web.

[0056] As shown in FIG. 2, central layer 30 is chosen such that when theconstituent web layers of laminate web 10 are processed by the method ofthe present invention, portions of central layer 30 in the region of themelt bond sites 50 separate to permit the first outer layer 20 to meltbond directly to the second outer layer 40 at the interface of the twomaterials 52 at melt bond sites 50. Thus, apertures in the central layer30 are formed in the lamination step by displacement, just prior to thebonding of the outer layers as detailed by the method of the presentinvention below. In this manner, central layer 30 can be provided as anunapertured web, avoiding complex registration steps to align aperturesin registry with bond sites when laminated. Further, central layer 30need not be thermally compatible with outer layers 20 and 40. Centrallayer need not be a thermoplastic material, and need not even have amelting point. It simply needs to be displaceable by the forces exertedby the processing equipment as detailed below. Therefore, one way ofdescribing the laminate web of the present invention is to distinguishthe central layer as being a material differentiated from the materialsof the first or second layers by at least one material property selectedfrom thermal properties, elongation properties, elastic properties, orconductive properties. By “thermal properties” is meant primarilythermal melt properties, such that the central layer has no meltingpoint, or if it has a melting point, it is preferably at least about 10degrees Centigrade higher, more preferably about 20 degrees Centigradehigher than either outer layer, and can be 100 degrees Centigrade higherthan either outer layer. By “elongation properties” is meant that intension, the material of the central layer exhibits an elongation tobreak that is at least 10% less than either outer layer, more preferably50% less than either outer layer, and can be greater than 100% less thaneither outer layer. Thus, the central layer can be extensible, whileeither outer layer can be highly extensible. By “elastic properties” ismeant that the central layer can be, for example, elastic, while eitherouter layer can be highly elastic, as defined herein. Or the centrallayer can be non-elastic, and the outer layers elastic or highlyelastic. By “conductive properties” as used herein is meant electricallyconductivity, such that the central layer can have an electricalconductivity that is 10 times, and more preferably 100 or more times asgreat as the outer layers. Conductive properties may be facilitated bythe central layer being a metallic foil, or by being a conductivepolymer, including a conductive nonwoven web.

[0057] Another advantage of the method of the present invention is that,in some embodiments, e.g., for solid core central layer 30 materials(i.e., a continuous sheet, that is, not having substantial apertures,gaps, or other voids), it results in a unitary web having an aperturedcentral layer 30 in full, intimate contact with the outer layers 20, and40. By “full” and “intimate” is meant that central layer 30 fills allthe unbonded regions between outer layers 20 and 40 such that outerlayers 20 and 40 do not contact except at the bond sites 50. Of course,it is recognized that many materials of interest have significant aircontent, and filling “all” the unbonded region between outer layers 20and 40 is not meant to imply that all air content is removed.

[0058] Central layer 30 can be involved, or participate, in the bondingbetween outer layers 20 and 40. By “involved” is meant that the centrallayer can, to some extent, be in intimate contact with, and possiblypartially merged with, one or both immediate outer layers. Theinvolvement may be due to actual melt bonding about the perimeter ofbond site 50 (e.g., for thermoplastic central layers 30), or it may bedue to mechanical interaction, such as by entanglement (e.g., forcellulosic fibrous central layer 30 between fibrous nonwoven layers),also about the perimeter of bond site 50. For example, FIG. 18-A showsin cross-section a unitary web comprising two outer nonwoven layers anda cellulosic tissue paper central layer. As can be seen, thelighter-colored central layer, due to the process of being “squeezed”apart, is intimately involved with the two outer layers at the bondsite.

[0059] Without being bound by theory, it is believed that the process ofthe present invention facilitates such separation of central layer 30 byshearing, cutting, or otherwise fracturing the central layer 30, anddisplacing the material of the central layer 30 sufficiently to permitthermal bonding of the two outer layers 20 and 40. Thus, central layer30 must be chosen to have properties that permit such displacement.Therefore, central layer 30 should have one or more of the properties ofrelatively low extensibility, relatively high frangibility, orrelatively high deformability, such that the material of central layer30 can be “squeezed” or otherwise displaced out of the region of thermalbond sites 50. Importantly, it is not required that the central layer 30be melted out of the region of the thermal bond sites. Thus, centrallayer can be elastic, highly elastic, extensible, or highly extensible,depending on the desired end results and purposes of the resultingunitary web.

[0060] Without being bound by theory, it is believed that to accomplishthe displacement of central layer 30 to form apertures therein and tobond the outer layers, the thermal point calendaring described belowshould form thermal bond sites having a narrow width W dimension and ahigh aspect ratio. For example, FIG. 3 shows the melt area of a singlemelt bond site 50 having a narrow width dimension W and a high aspectratio, i.e., the length, L, is much greater than the width, W. Thelength L should be selected to permit adequate bond area while width Wis sufficiently narrow such that the protuberance used to form the bondsite (as described below) can cut, shear, displace, or otherwise piercethe central layer 30 at the region of the bond sites by the methoddescribed below. Width W can be between about 0.003 inches and 0.020inches, but in a preferred embodiment, is between about 0.005 inches and0.010 inches, and may be adjusted depending on the properties of centrallayer 30.

[0061] It is believed that the aspect ratio of melt bond site 50 can beas low as about 3 (i.e., ratio of L/W equals 3/1). It can also bebetween about 4 and 20. In one preferred embodiment, the aspect ratiowas about 10. It is believed that the aspect ratio of the melt bondsites 50 is limited only by the corresponding aspect ratio of the pointbonding protuberances of the calendaring roller(s), as detailed below.

[0062] In a preferred embodiment, the longitudinal axis of each bondsite, 1, which corresponds directionally to the length dimension of bondsite 50, is disposed in a regular, repeating pattern oriented generallyparallel to the machine direction, MD as shown in FIG. 1. But thelongitudinal axis of each bond site may be disposed in a regular,repeating pattern oriented in the cross machine direction, or randomlyoriented in a mixture of cross and machine directions. For example, thebond sites 50 can be disposed in a “herringbone” pattern.

[0063] When nonwoven webs are used as constituent layers of laminate 10,an important distinction should be drawn between bond sites 50 whichbond together outer layers 20 and 40 by the method of the presentinvention, and thermal bond sites that may be present in the constituentlayers themselves. For example, nonwoven webs are typically consolidatedby thermal bonding in a regular pattern of discrete spaced apart fusedbonding areas, such as the pattern disclosed in U.S. Pat. No. 3,855,046to Hansen et al., and the patterns shown generally in FIGS. 10 and 11 ofU.S. Pat. No. 5,620,779 to Levy et al. Other films, nonwoven webs, andthe like may have thermal embossments for aesthetic reasons. Therefore,in the unitary web 10 there may be many thermal bond sites, some ofwhich are bond sites 50, and others which are bond sites in the basenonwoven, for example.

[0064] The bond sites of the base nonwoven do not typically have anaspect ratio greater than about 1, so that these bonds do not typicallyform apertures in the constituent layer during the stretching stepdisclosed below. Also, the spacing of such bond sites is typically arepeating pattern of bonded and unbonded area which may or may notprovide for machine direction (MD) columns of bonded area next tocolumns of unbonded area. After forming bond sites 50, however, there isnot likely to be any significant MD columns of unbonded areas; theoverall bond pattern of any constituent nonwoven fabric is a combinationof existing bonded areas and bond sites 50. Together the two sets ofbond sites result in a complex pattern of bond sites that may or may notbe described as columnar, regular, or uniform.

[0065] The resulting web of the present invention, as shown incross-section in FIG. 2, is a laminate web 10 that is itselfunapertured, but the central layer 30 is apertured coincident theregions of the bond sites 50. As stated above, by “unapertured” is meantthat, on the whole, the laminate web 10 is considered unapertured. It isrecognized that the un-apertured laminate web 10 of the presentinvention may have localized cut through, or tearing at bond sites 50due to materials and processing variability or post lamination handling.Ideally, such cut through of the entire web is minimized and eliminated.Likewise, it is recognized that in some instances, there may not becomplete displacement of the central layer 30 at all locations of bondsites 50 such that some localized portions of central layer 30 may notbe apertured (and the outer layers not bonded). Nevertheless, thedescription herein is made for the laminate web 50 as a whole, and isnot meant to be limited by aberrations or anomalies due to potentialmaterial or processing variables.

[0066] To produce the webs of the present invention, including asdescribed in FIG. 2, the outer layers should have sufficient elongationto permit the necessary local deformation in the immediate vicinity ofbond sites 50. Thus, the outer layers 20 and 40 can be extensible,highly extensible, elastic, or highly elastic.

[0067] The central layer 30 itself need not be thermally compatible withthe outer layers. The central layer 30 need not even be meltprocessible. It can be, for example, a cellulosic material, such aspaper; a metallic material, such as a metal foil; a woven or knitmaterial, such as cotton or rayon blends; or a thermoset material, suchas a polyester or aromatic polyamide film. The central layer 30 can beanother nonwoven having suitable properties for processing into anapertured layer. If central layer 30 has a melting point, it ispreferably at least about 10 degrees Centigrade higher, more preferablyabout 20 degrees Centigrade higher than the outer layers. In certainembodiments, for example a metal foil central layer 30 betweenthermoplastic nonwoven outer layers, the central layer can have amelting point at least 100 degrees Centigrade higher than the outerlayers. However, central layer 30 need not have a melting point, and maysimply experience softening at the calendaring temperatures required tobond the laminate. In certain central layer materials, such as metalfoils, there may not be any softening due to thermal processing of theweb.

[0068] The wide range of possible central layer materials permits asurprising variety of structures of the present invention, each havingbeneficial application in a wide assortment of end uses. For example,when outer layers of nonwoven material are used with a central layer ofmetal foil, the resulting laminate is a flexible, soft, formable,conductive web that is relatively quiet when folded, crumpled orotherwise deformed. Such a material can be used in applicationsrequiring electrical shielding, for example. When a central layer oftissue paper is used, the resulting laminate is a soft, bulky, absorbentweb. Such a laminate is suitable for use as a wiping implement, forexample. Further, since the laminate web 10 is formed without the use ofthermoplastic adhesives, durable, garment-like properties can beobtained. Such laminates can be laundered a number of times beforesuffering unacceptable wear.

[0069] By way of example, laminate web 10 can be a conductive fabriccomprising relatively non-conductive thermoplastic outer layers 20 and40 and a relatively conductive central layer 30. The outer layers can benon-woven webs for a low cost, soft, breathable conductive fabric. Thecentral layer can be a metal foil, such as a copper foil or an aluminumfoil. The central layer can also be a conductive polymer, a non-foilconductive fabric, or a composite conductive material. In general, as aconductive fabric embodiment, the outer layers should serve to insulatethe conductive central layer(s). In a preferred three-layer embodimentthe outer layers each have a first electrical resistance and the centrallayer has a second electrical resistance which is at least one-tenth thefirst electrical resistance, more preferably one-hundredth (i.e., thecentral layer is 10 times, preferably 100 times as conductive as theouter layers).

[0070] A conductive laminate web 10 can find use as a sheet ofconductive material for signal propagation. It can also find use as ashielding material. In particular, the aspect ratio of the bond sites 50can be predetermined for particular shielding characteristics. Byaltering the length, width, and orientation of the bond sites 50 certainwave propagation of electromagnetic waves can be altered or stopped. Forexample, the bond sites 50, which represent penetration of theconductive central layer, can be designed to be effective in filteringcertain wavelengths of electromagnetic radiation. In addition to theelectrical characteristics of such a web, the laminate web 10 can be,and preferably is, very flexible and formable, such that the conductiveor shielding benefits can be applied in a non-planar fashion. Forexample, sensitive electronic equipment can be wrapped with a fabricshield.

[0071] A further benefit of the present invention is the capability tocombine both thermoplastic and non-thermoplastic materials without anyadhesives, to provide fabric-like composites having unique physicalproperties. For example, a material having high tensile strength andresistance to tear can include as a central layer 30 TYVEK®, availablefrom DuPont, Wilmington Del., USA. TYVEK®, and equivalent or similarmaterials under other tradenames, is an extremely strong but breathablepolyolefin nonwoven, commonly used as a house-wrap layer. However, it isnot soft and clothlike, but has the look and feel of a plastic film.When used in a laminate web 10 of the present invention, for examplewith nonwoven outer layers, the laminate web exhibits the softness of anonwoven with the strength of the TYVEK® layer. Again, this laminate canbe, and is preferably, made without the use of adhesives to bind the webinto a unitary web.

[0072] Further, relatively strong materials such as TYVEK® can becombined with additional central layers 30 to make laminate webs 10having a variety of physical properties. For example, a laminate webcomprising a TYVEK® layer can also comprise an absorbent layer, such alayer of absorbent tissue paper, such as BOUNTY® paper towel, availablefrom The Procter & Gamble Co., Cincinnati Ohio, USA and one or moreouter layers of polyethylene nonwoven (e.g. Corolind, available fromBBA, Simpsonville, S.C., USA). Such a composite formed according to themethod of the present invention can be transformed into a highlytextile-like material, exhibiting the unusual combined properties ofrelatively high absorbency (from the BOUNTY® paper towel layer(s)), andrelatively high strength (from the TYVEK® layer(s)).

[0073] Apertured Embodiments

[0074] A further benefit of the present invention is obtained when thenon-apertured thermally bonded laminate web described above is stretchedor extended in a direction generally orthogonal to the longitudinalaxis, 1, of melt bond sites 50. The melt bonding at the melt bond sites50 tends to make localized weakened portions of the web at the bondsites. Thus, as portions of the web 10 are extended in a directiongenerally orthogonal to the longitudinal axis I of bond sites 50, thematerial at the bond site fails in tension and an aperture is formed.The relatively high aspect ratio of melt bond sites 50, permits arelatively large aperture to be formed upon sufficient extension. Whenthe laminate web 10 is uniformly tensioned, the result is a regularpattern of a plurality of apertures 60 corresponding to the pattern ofmelt bond sites 50.

[0075]FIG. 4 shows a partially cut-away representation of an aperturedlaminate of the present invention. As shown, the partial cut-awaypermits each layer or ply to be viewed in a plan view. The laminate web10 shown in FIG. 4 is produced after the thermally bonded laminate isstretched in a direction orthogonal to the longitudinal axis of the meltbond sites, in this case, in the cross-machine direction, CD withsufficient elongation in the direction of extension to cause aperturesto form. As shown, where formerly were melt bond sites 50, apertures 60are produced as the relatively weak bond sites fail in tension. Also asshown, central layer 30 can remain generally uniformly distributedwithin laminate 10, depending on the material properties of centrallayer 30. For example, if central layer 30 is more extensible than outerlayers 20 or 40, then it simply extends, either elastically or byplastic deformation, but remains generally uniformly distributed in theunapertured regions of web 10. For example, if a thermoplastic film isutilized as the central layer 30, it extends, either extensibly orelastically (depending on the type of film), but can remain generallyuniform, for example, in density or basis weight.

[0076] When apertures 60 are formed, the thermally bonded portions ofouter layers 20 and 40 remain primarily on the portions of the apertureperimeters corresponding to the length dimension of bond sites 50.Therefore, each aperture 60 does not have a perimeter of thermallybonded material, but only portions remain bonded, represented as 62 inFIG. 4. One beneficial property of such a laminate web is that onceapertured, fluid communication with the central layer is facilitated.Thus, an absorbent central layer 30 can be used between two relativelynon-absorbent outer layers, and the laminate 10 could be an absorptivewiper with a relatively dry to the touch outer surface.

[0077] To the extent that central layer 30 is involved, or participates,in any bonding between outer layers 20 and 40, it also participates inthe remnant of bonded portions 62, as shown in FIG. 4. The involvementmay be due to some degree of actual melt bonding about the perimeter ofbond site 50 (e.g., for thermoplastic central layers 30 ), or it may bedue to mechanical interaction, such as by entanglement (e.g., forcellulosic fibrous central layer 30 between fibrous nonwoven layers).

[0078]FIG. 5 is a schematic representation of the cross-section denotedin FIG. 4. As shown, apertures 60 form when the laminate web iselongated in the direction T.

[0079] Another benefit of the present invention is obtained when thelaminate is extended as described with reference to FIG. 4, but thecentral layer 30 is chosen to have an elongation to break less thaneither of the two outer layers, and less than the actual magnitude ofextension. Thus, upon extension of the laminate web generally orthogonalto the longitudinal axis, 1, sufficient to form apertures in outerlayers 20 and 40 (and thus the entire laminate web 10) central layer 30fails in tension. Therefore, central layer 30 fractures (i.e., fails intension) upon sufficient extension, such that after extension centrallayer 30 is no longer uniformly distributed over the non-aperturedregions of the laminate web 10.

[0080] An example of one embodiment of a unitary web having a centrallayer having an elongation to break less than either of the two outerlayers, and less than the actual magnitude of extension, is shownpartially cut-away in FIG. 5. The partial cut-away permits each layer orply to be viewed in a plan view. As shown, after extension, centrallayer 30 becomes fragmented, forming discontinuous regions of thecentral layer material. These discontinuous regions may be relativelyuniformly distributed, such as in rows as shown in FIG. 5, or may berelatively randomly distributed, depending on the pattern of melt bondsites 50, the physical properties of central layer 30, and the method ofextension employed.

[0081] One example of a web 10 having a structure similar to that shownin FIG. 5 is a web having outer layers of relatively extensiblenonwovens, with a central layer of relatively low extensibility tissuepaper. Such a laminate would be an apertured laminate web having anabsorbent central core, wherein the absorbent core material is in fluidcommunication with regions exterior to the laminate web. That is, forexample, if such a laminate web comprised nonwoven outer layers, itcould be used as an absorbent wiper. Fluids could thus be absorbed viathe apertures, the perimeter of which can be open at portions whichprovide fluid communication to the absorbent central core. If arelatively hydrophobic nonwoven web is used for the outer layers, such awiper could exhibit dry-to-the-touch properties along with highabsorbency.

[0082] One example of a web 10 having a structure similar to that shownin FIG. 5 is a web having outer layers of relatively extensiblenonwovens, with a central layer of relatively low extensibility tissuepaper. One particularly interesting structure incorporates a highlyhydrophobic outer layer combined with a highly absorbent central layer.A suitable hydrophobic material is described in U.S. Pat. No. 3,354,022Dettre et al. Such a material has a water repellent surface having anintrinsic advancing water contact angle of more than 90 degrees and anintrinsic receding water contact angle of at least 75 degrees. Such amaterial exhibits extremely hydrophobic properties, similar to theeffect known to exist on leaves from the Lotus plant. When such amaterial is combined with an absorbent central layer, such as a BOUNTY®paper towel tissue layer, the resulting composite can be highlyabsorbent while retaining a very clean and dry outer surface. The basisweight and porosity of the outer layer can be varied to achievedifferent degrees of absorbent performance. In one embodiment thelaminate could also be post-laminated to a fluid-impervious backinglayer to form an absorbent fluid barrier. The fluid-impervious backinglayer could be a flexible polymeric film for use such absorbent articlesas sanitary napkins, diapers, place mats, floor mats, protective covers,and the like.

[0083] One surprising beneficial characteristic of the laminate webstructure of the present invention described with reference to FIG. 6 isthe presence of distinct regions in the non-apertured portion of the webbeing differentiated by at least one property selected from the groupconsisting of basis weight, thickness, or density. As shown in thecross-section of FIG. 7, several such regions can be differentiated. Ina preferred embodiment, the regions are visually distinct, giving thelaminate an aesthetically pleasing look and feel. The regions may alsogive the laminate a garment-like or knit-like texture and hand.

[0084] With reference to FIG. 7, several structurally distinct regionscan be identified in the cross-section shown. The region denoted 64corresponds to the aperture 60. In the non-apertured area of the web, aregion 66 is a relatively high basis weight region comprising centrallayer 30. Region 68 represents the portion of the laminate web in whichcentral layer 30 has fractured and separated, i.e., is no longer fullypresent, forming a relatively low basis weight region of web 10. Ingeneral, the higher basis weight regions will also be correspondinglyhigher density regions, but need not be so. For example, apost-extension embossing process can be applied to web 10 to formregions of multiple densities in addition to the regions of multiplebasis weight. For either the high basis weight regions or the highdensity regions, often the differences can be discernible by simplyrubbing the laminate web between the fingers.

[0085] In general, for a laminate web 10 having generally parallel rowsof melt bond sites 50 extending in the machine direction MD, whichcorrespondingly form generally parallel rows of apertures when extended,and having a central layer with a lower elongation to break than theouter layers, the resulting extended, apertured laminate web 10 ischaracterized by generally low basis weight, low density regions betweenthe apertures in the machine direction, MD, e.g., region 68 in FIGS. 6and 7. Likewise, such a laminate web 10 is characterized by relativelyhigh basis weight, high density regions between adjacent rows ofapertures in the cross-machine direction, CD, e.g., region 66 in FIG. 7.By choice of central layer material 30 and possibly post laminatingoperations, e.g., an embossing process, the thickness of the laminateweb can likewise be varied, the thicker regions generally correspondingto the higher density regions.

[0086] On particularly useful embodiment of a laminate web as describedwith reference to FIG. 7, is a conductive fabric for signal transmissionvia a plurality of closely-spaced, parallel signal conductors. Forexample, if a conductive metal foil is used as central layer 30, uponsufficient extension in the CD by the incremental stretching operationdescribed below, the metal foil fractures into a plurality of discreteconductive ribbons corresponding to the high basis weight region 66 ofFIG. 7. Outer layers 20 and 40 are preferably chosen for theirinsulating properties, and are, therefore, preferably thermoplasticpolymeric material. For high-speed transmission of electrical signals, alow-dielectric material, such as polytetrafluoroethylene (PTFE), andpreferably expanded PTFE (e.g., GORE-TEX® available from W. L. Gore andAssociates, Newark, Del., USA) can be used as the insulating outerlayers. Additional outer layers can be added (e.g., post laminateformation), including additional conductive layers to form a shieldedribbon cable. Figure X shows an example of such a conductive ribbon . ..

[0087] Another embodiment of a laminate web of the present inventionutilizing nonwoven webs as the outer layers is characterized by distinctregions differentiated by fiber orientation. Differential fiberorientation can be achieved by providing for localized regions withinthe web that experience greater extension than other regions. Forexample, by locally straining the web 10 to a greater degree in theregions corresponding to regions 68 in FIG. 6, regions of significantfiber reorientation are formed. Such localized straining is possible bythe method of the present invention detailed below.

[0088]FIG. 8 is a photomicrograph showing in magnified detail a web ofthe present invention comprising nonwoven outer layers which has beenextended to form apertures, and locally extended to produce regions 68of fiber reorientation. As can be seen in FIG. 8, by locally extendingportions of the web to a greater extent than others, the aperturesformed thereby can be of different sizes. Thus, the region denotedgenerally as 70 in FIG. 8 has undergone more strain (i.e., localextension) than the region denoted by 72. Thus, the apertures in region70 are larger than those in region 72, and the basis weight of thenonwoven web material in region 72 is less than the basis weight of thenonwoven web in region 70. In addition to the difference in basis weightdue to localized strain differentials, the laminate web of the presentinvention can also exhibit distinct regions 68 of fiber reorientation.In these regions, the fibers have been reoriented from a generallyrandom orientation to a predominant orientation in the direction ofextension.

[0089] To make a web 10 as shown in FIG. 6, central layer 30 can be anyof a great number of dissimilar materials. For example, if outer layers20 and 40 are nonwoven webs having a relatively high elongation tobreak, central layer 30 can be paper, tissue paper, thermoplastic film,metal foil, closed or open cell foam, or any other material that has arelatively low elongation to break compared to the two outer layers. Theouter layer materials may themselves be dissimilar, with the onlyconstraint being that the central layer be relatively less extensible inthe direction of extension to form apertures.

[0090] Additionally, more than one central layer 30 can be used withbeneficial results. For example, a structure comprising a cellulosictissue central web and a polymeric film central web between two nonwovenwebs can produce an absorptive wiping article with one side beingrelatively more absorptive than the other. If the film layer is athree-dimensional formed film, the film side can provide added textureto the laminate which is beneficial in many wiping applications.Macroscopically-expanded, three-dimensional formed films suitable foruse in the present invention include those described incommonly-assigned U.S. Pat. No. 3,929,135 issued to Thompson on Dec. 30,1975, and U.S. Pat. No. 4,342,314 issued to Radel et al. on Aug. 3,1982, both patents hereby incorporated herein by reference.

[0091] The (or “a”) central layer can also be elastomeric, and can be anelastomeric macroscopically-expanded, vacuum-formed, three-dimensionalformed film, such as described in commonly-assigned U.S. Ser. No.08/816,106, entitled “Tear Resistant Porous Extensible Web” filed byCurro et al. on Mar. 14, 1997, and hereby incorporated herein byreference. Further, the (or “a”) central layer can be athree-dimensional formed film having micro-apertures such as describedin commonly-assigned U.S. Pat. No. 4,629,643 issued to Curro et al. onDec. 16, 1986, and 4,609,518, issued to Curro et al. on Sep. 2, 1986,both of which are hereby incorporated herein by reference.

[0092] The (or “a”) central layer can be a web material having astrainable network as disclosed in U.S. Pat. No. 5,518,801 issued toChappell et al. on May 21, 1996, and hereby incorporated herein byreference. Such a web can be a structural elastic-like film (SELF) web,formed by, for example, embossing by mating plates or rolls.

[0093] The (or “a”) central layer can be an absorbent open cell foam webmaterial. Particularly suitable absorbent foams for high performanceabsorbent articles such as diapers have been made from High Internalphase Emulsions (hereafter referred to as “HIPE”). See, for example,U.S. Pat. No. 5,260,345 (DesMarais et al), issued Nov. 9, 1993 and U.S.Pat. No. 5,268,224 (DesMarais et al), issued Dec. 7, 1993, herebyincorporated herein by reference. These absorbent HIPE foams providedesirable fluid handling properties, including: (a) relatively goodwicking and fluid distribution characteristics to transport the imbibedurine or other body fluid away from the initial impingement zone andinto other regions of the foam structure to allow for subsequent gushesof fluid to be accommodated; and (b) a relatively high storage capacitywith a relatively high fluid capacity under load, i.e. under compressiveforces.

[0094] The central layer 30 may comprise absorbent gelling materials.For example, supersorbers or hydrogel materials may provide for superiorabsorbency when the laminate web of the present invention is used as anabsorbent wipe or an absorbent core in a disposable absorbent article.By “hydrogel” as used herein is meant an inorganic or organic compoundcapable of absorbing aqueous fluids and retaining them under moderatepressures. For good results the hydrogels should be water insoluble.Examples are inorganic materials such as silica gels and organiccompounds such as cross-linked polymers. Cross-linking may be bycovalent, ionic, vander Waals, or hydrogen bonding. Examples of polymersinclude polyacrylamides, polyvinyl alcohol, ethylene maleic anhydridecopolymers, polyvinyl ethers, hydroxypropyl cellulose, carboxymethylcellulose, polyvinyl pyridine and the like.

[0095] One benefit of the laminate of the present invention is theability to make a laminate structure of dissimilar materials without theuse of adhesive for joining. Because the central layer of the laminateweb 10 is penetrated by the protuberances of the calendaring roll atmelt bond sites, it can comprise non-thermally-bondable materials. Theplurality of melt bond sites 50 are sufficient to keep the componentwebs together in the laminate web, so that the laminate web behaves as aunitary web for processing integrity and use, without unwanteddelamination. However, in some embodiments, and for certain materials,it may be beneficial to apply adhesive between at least two of theconstituent layers.

[0096] The laminate web of the present invention, being bonded by aplurality of relatively closely spaced thermal bond sites (without theuse of thermoplastic adhesives) can be beneficially used for durablearticles. For example, a laminate web of the present inventioncomprising nonwoven web outer layers and having a clothlike feel andappearance, can be used in durable garments. Certain embodiments of thelaminate web of the present invention can survive repeated washing anddrying in household washing and drying equipment, depending on thecomponent webs of the laminate, and the level of thermal bonding. Due tothe knit-like or fabric-like look and feel of certain embodiments of thepresent invention, such durability can result in durable garmentcomponents such as interliners and the like.

[0097] Method of Making

[0098] Referring to FIG. 9 there is schematically illustrated at 100 aprocess making a laminate web of the present invention.

[0099] A first web 120 which can be a relatively extensible web, isunwound from a supply roll 104 and travels in a direction indicated bythe arrows associated therewith as the supply roll 104 rotates in thedirection indicated by the arrows associated therewith. Likewise asecond web 140, which can be a relatively extensible web is unwound fromsupply roll 105. A central layer 130, which can be a relativelyinextensible layer, is likewise drawn from supply roll 107. The threecomponents (or more, if more than one central layer is used) passthrough a nip 106 of the thermal point bond roller arrangement 108formed by rollers 110 and 112.

[0100] In addition to thermoplastic nonwoven materials, either outerlayer can comprise a polymeric film, for example a polyolefinic (e.g.,PP or PE) thin film. If the entire outer layer is not uniformlythermoplastic, at least sufficient amounts to effect melt bonding mustbe thermoplastic. Conjugate fibers, such as bicomponent fibers can beused in the outer layers to facilitate thermal bonding of the outerlayers. Either outer layer can comprise a formed film, such as athree-dimensional formed film having micro-apertures such as describedin commonly-assigned U.S. Pat. No. 4,629,643 issued to Curro et al. onDec. 16, 1986, and 4,609,518, issued to Curro et al. on Sep. 2, 1986,both of which are hereby incorporated herein by reference.

[0101] In a preferred embodiment, both outer layers comprise nonwovenmaterials, and may be the identical. The nonwoven material may be formedby known nonwoven extrusion processes, such as, for example, knownmeltblowing processes or known spunbonding processes, and passeddirectly through the nip 106 without first being bonded and/or stored ona supply roll. However, in a preferred embodiment, the nonwoven webs arethemselves thermally point bonded (consolidated) webs commerciallyavailable on supply rolls. The thermal point bonds, which are typicallyin the form of a regular pattern of spaced-apart diamond shaped bondsites, are present in the nonwoven as purchased from a nonwoven vendor,and are to be distinguished in the web of the present invention from thebond sites 50 formed by the method of the present invention.

[0102] The nonwoven web outer layer(s) may be elastic, highly elastic ornonelastic. The nonwoven web may be any melt-fusible web, including aspunbonded web, a meltblown web, or a bonded carded web. If the nonwovenweb is a web of meltblown fibers, it may include meltblown microfibers.The nonwoven web may be made of fiber forming polymers such as, forexample, polyolefins. Exemplary polyolefins include one or more ofpolypropylene, polyethylene, ethylene copolymers, propylene copolymers,and butene copolymers. The nonwoven web can have a basis weight betweenabout 10 to about 60 grams per square meter (gsm), and more preferablyabout 15 to about 30 gsm.

[0103] The nonwoven web outer layers may themselves be a multilayermaterial having, for example, at least one layer of a spunbonded webjoined to at least one layer of a meltblown web, a bonded carded web, orother suitable material. For example, the nonwoven web may be amultilayer web having a first layer of spunbonded polypropylene having abasis weight from about 0.2 to about 8 ounces per square yard, a layerof meltblown polypropylene having a basis weight from about 0.2 to about4 ounces per square yard, and a second layer of spunbonded polypropylenehaving a basis weight from about 0.2 to about 8 ounces per square yard.Alternatively, the nonwoven web may be a single layer of material, suchas, for example, a spunbonded web having a basis weight from about 0.2to about 10 ounces per square yard or a meltblown web having a basisweight from about 0.2 to about 8 ounces per square yard.

[0104] The nonwoven web outer layers may also be a composite made up ofa mixture of two or more different fibers or a mixture of fibers andparticles. Such mixtures may be formed by adding fibers and/orparticulates to the gas stream in which meltblown fibers or spunbondfibers are carried so that an intimate entangled co-mingling of fibersand other materials, e.g., wood pulp, staple fibers and particles occursprior to collection of the fibers.

[0105] Prior to processing by the method of the present invention, thenonwoven web outer cover of fibers can be joined by bonding to form acoherent web structure. Suitable bonding techniques include, but are notlimited to, chemical bonding, thermobonding, such as point calendering,hydroentangling, and needling.

[0106] Referring to FIGS. 9 and 10, the nonwoven thermal bond rollerarrangement 108 preferably comprises a patterned calendar roller 110 anda smooth anvil roller 112. One or both of the patterned calendar roller110 and the smooth anvil roller 112 may be heated and the temperature ofeither roller and the pressure between the two rollers may be adjustedby well known means to provide the desired temperature, if any, andpressure to concurrently displace central layer 30 at melt bond sites,and melt bond the two outer layers together at a plurality of bondsites.

[0107] The patterned calendar roller 110 is configured to have acircular cylindrical surface 114, and a plurality of protuberances orpattern elements 116 which extend outwardly from surface 114. Theprotuberances 116 are disposed in a predetermined pattern with eachprotuberance 116 being configured and disposed to displace central layer30 at melt bond sites, and melt bond the two outer layers together at aplurality of locations. One pattern of protuberances is shownschematically in FIG. 11. As shown, the protuberances 116 have arelatively small width, WP, which can be between about 0.003 inches and0.020 inches, but in a preferred embodiment is about 0.010 inches.Protuberances can have a length, LP, of between about 0.030 inches andabout 0.200 inches, and in a preferred embodiment has a length of about0.100 inches. In a preferred embodiment, the protuberances have anaspect ratio (LP/WP) of 10. The pattern shown is a regular repeatingpattern of staggered protuberances, generally in rows, each separated bya row spacing, RS, of about between about 0.010 inches and about 0.200inches. In a preferred embodiment, row spacing RS is about 0.060 inches.The protuberances can be spaced apart within a row by a protuberancespacing, PS generally equal to the protuberance length, LP. But thespacing and pattern can be varied in any way depending on the endproduct desired.

[0108] As shown in FIG. 10, patterned calendar roller 110 can have arepeating pattern of protuberances 116 which extend about the entirecircumference of surface 114. Alternatively, the protuberances 116 mayextend around a portion, or portions of the circumference of surface114. Likewise, the protuberances 116 may be in a non-repeating pattern,or in a repeating pattern of randomly oriented protuberances. Of course,if randomly oriented, the opening of the resulting bond sites intoapertures will also be somewhat random, depending on the orientation ofthe bond site with respect to the direction of tension, as discussedbelow. For example, if the web is tensioned in the cross-direction (CD)direction only, then the bond sites 50 having a longitudinal axis 1 witha vector component in the machine direction (MD) will open into anaperture, at least to the degree of the magnitude of such a vectorcomponent.

[0109] The protuberances 116 are preferably truncated conical shapeswhich extend radially outwardly from surface 114 and which haverectangular or somewhat elliptical distal end surfaces 117. Although itis not intended to thereby limit the scope of the present invention toprotuberances of only this configuration, it is currently believed thatthe high aspect ratio of the melt bond site 50 is only achievable if theprotuberances likewise have a narrow width and a high aspect ratio atthe distal end surfaces 117, as shown above with reference to FIG. 11.The roller 110 is preferably finished so that all of the end surfaces117 lie in an imaginary right circular cylinder which is coaxial withrespect to the axis of rotation of roller 110.

[0110] The height of the protuberances should be selected according tothe thickness of the laminate being bonded. In general, the heightdimension should be greater than the maximum thickness of the laminateweb during the calendaring process, so that adequate bonding occurs atthe bond sites, and only at the bond sites.

[0111] Anvil roller 112, is preferably a smooth surfaced, right circularcylinder of steel.

[0112] After passing through nip 106, the three (or more) component webs120, 130, and 140 have been formed into unitary laminate web 10. At thispoint in the process the outer layers are thermally bonded to each otherand unapertured, as shown in FIGS. 1 and 2. Central layer(s) 30, fromweb 130, is apertured, having been displaced by protuberances 116 in nip106. Depending on the central layer(s) used, it (they) may or may notparticipate in the bonding about the periphery of the bond sites. Insome instances, particularly for non-thermoplastic, non-fibrousmaterials, central layer may not be involved in the bonding of the outerlayers at all. However, for thermoplastic materials, and fibrousmaterials, some involvement of the central layer(s) is observed.

[0113] The laminate web 10 may be further processed to form apertures inthe whole laminate web (or portions thereof) by extending portions ofthe web in a direction orthogonal to the axis I of bond sites 50. Asshown in FIGS. 9 and 10, the axis 1 is generally parallel to the machinedirection MD of the web being processed. Therefore, extension in thecross-direction CD at the bonded portions causes the bond sites 50 torupture and open to form apertures in the web.

[0114] One method for forming apertures across the web is to pass theweb through nip 130 formed by an incremental stretching system 132employing opposed pressure applicators 134 and 136 havingthree-dimensional surfaces which at least to a degree are complementaryto one another. Stretching of the laminate web may be accomplished byother methods known in the art, including tentoring, or even by hand.However, to achieve even strain levels across the web, and especially iflocalized strain differentials are desired, the incremental stretchingsystem disclosed herein is preferred.

[0115] Referring now to FIG. 12, there is shown a fragmentary enlargedview of the incremental stretching system 132 comprising incrementalstretching rollers 134 and 136. The incremental stretching roller 134includes a plurality of teeth 160 and corresponding grooves 161 whichextend about the entire circumference of roller 134. Incrementalstretching roller 136 includes a plurality of teeth 162 and a pluralityof corresponding grooves 163. The teeth 160 on roller 134 intermesh withor engage the grooves 163 on roller 136, while the teeth 162 on roller136 intermesh with or engage the grooves 161 on roller 134. The teeth ofeach roller are generally triangular-shaped, as shown in FIG. 13. Theapex of the teeth may be slightly rounded, if desired for certaineffects in the finished web.

[0116]FIG. 13, shows a portion of the intermeshing of the teeth 160 and162 of rollers 134 and 136, respectively. The term “pitch”as usedherein, refers to the distance between the apexes of adjacent teeth. Thepitch can be between about 0.02 to about 0.30 inches, and is preferablybetween about 0.05 and about 0.15 inches. The height (or depth) of theteeth is measured from the base of the tooth to the apex of the tooth,and is preferably equal for all teeth. The height of the teeth can bebetween about 0.10 inches and 0.90 inches, and is preferably about 0.25inches and 0.50 inches.

[0117] The teeth 160 in one roll can be offset by one-half the pitchfrom the teeth 162 in the other roll, such that the teeth of one roll(e.g., teeth 160) mesh in the valley (e.g., valley 163) between teeth inthe mating roll. The offset permits intermeshing of the two rollers whenthe rollers are “engaged” or in an intermeshing, operative positionrelative to one another. In a preferred embodiment, the teeth of therespective rollers are only partially intermeshing. The degree to whichthe teeth on the opposing rolls intermesh is referred to herein as the“depth of engagement” or “DOE” of the teeth. As shown in FIG. 13, theDOE, E, is the distance between a position designated by plane P1 wherethe apexes of the teeth on the respective rolls are in the same plane(0% engagement) to a position designated by plane P2 where the apexes ofthe teeth of one roll extend inward beyond the plane P1 toward thevalley on the opposing roll. The optimum or effective DOE for particularlaminate webs is dependent upon the height and the pitch of the teethand the materials of the web.

[0118] In other embodiments the teeth of the mating rolls need not bealigned with the valleys of the opposing rolls. That is, the teeth maybe out of phase with the valleys to some degree, ranging from slightlyoffset to greatly offset.

[0119] As the laminate web 10 having melt bonded locations 50 passesthrough the incremental stretching system 132 the laminate web 10 can besubjected to tensioning in the CD or cross-machine direction causing thelaminate web 10 to be extended in the CD direction. Alternatively, oradditionally, the laminate web 10 may be tensioned in the MD (machinedirection). The tensioning force placed on the laminate web 10 can beadjusted (e.g., by adjusting DOE) such that it causes the melt bondedlocations 50 to separate or rupture creating a plurality of apertures 60coincident with the melt bonded locations 50 in the laminate web 10.However, portions of the melt bonds of the laminate web 10 remain, asindicated by portions 62 in FIG. 4, thereby maintaining the laminate webin a coherent, unitary web condition even after the melt bondedlocations rupture.

[0120] After being subjected to the tensioning force applied by theincremental stretching system 132, the laminate web 10 includes aplurality of apertures 60 which are coincident with the melt bondedregions 50 of the laminate web. As mentioned, a portion of thecircumferential edges of apertures 60 include remnants 62 of the meltbonded locations 60. It is believed that the remnants 60 help to resistfurther tearing or delamination of the laminate web. Remnants 62 mayalso contain portions of central layer 30, to the extent that thecentral layer is involved in the bonding.

[0121] Instead of two substantially identical rolls 134 and 136, one orboth rolls can be modified to produce extension and additionalpatterning. For example, one or both rolls can be modified to have cutinto the teeth several evenly-spaced thin channels 246 on the surface ofthe roll, as shown on roll 236 in FIG. 14. In FIG. 14 there is shown anenlarged view of an alternative incremental stretching system 232comprising incremental stretching rollers 234 and 236. The incrementalstretching roller 234 includes a plurality of teeth 260 andcorresponding grooves 261 which extend about the entire circumference ofroller 234. Incremental stretching roller 236 includes a plurality ofteeth 262 and a plurality of corresponding grooves 263. The teeth 260 onroller 234 intermesh with or engage the grooves 263 on roller 236, whilethe teeth 262 on roller 236 intermesh with or engage the grooves 261 onroller 234. The teeth on one or both rollers can have channels 246formed, such as by machining, such that regions of undeformed laminateweb material may remain after stretching. A suitable pattern roll isdescribed in U.S. Pat. No. 5,518,801, issued May 21, 1996, in the nameof Chappell, et al., the disclosure of which is incorporated herein byreference.

[0122] Likewise, the incremental stretching can be by mating rollsoriented as shown in FIG. 15. Such rolls comprise a series of ridges360, 362, and valleys, 361, 363 that run parallel to the axis, A, of theroll, either 334 or 336, respectively. The ridges form a plurality oftriangular-shaped teeth on the surface of the roll. Either or both rollsmay also have a series of spaced-apart channels 346 that are orientedaround the circumference of the cylindrical roll. Rolls as shown areeffective in incrementally stretching a laminate web 10 in the machinedirection, MD if the axis 1 of bond sites 50 is oriented generallyparallel to the cross-machine, CD direction of the web as its beingprocessed.

[0123] In one embodiment, the method of the present invention cancomprise both CD and MD incremental stretching. As shown in FIG. 16, twopairs of incremental stretching rolls can be used in line, such that onepair (232, which, as shown in FIG. 16 includes a series of spaced-apartchannels 246) performs CD stretching, and another pair, 332 performs MDstretching. By this method many interesting fabric-like textures can bemade. The resulting hand and visual appearance make such fabric-likewebs ideal for use in articles benefiting from a fabric-like look andfeel. For example, if a central layer 30 comprises a material havingless elongation to break than either outer layer, and is stretched tofailure in both the CD and MD directions by the method described herein,the resulting laminate web 10 exhibits “islands” of central layermaterial. The islands are discrete, non-continuous portions of centrallayer, and give the laminate web 10 a decidedly fabric-like look andfeel. In this manner, if a metal foil is used as a central layer 30between two relatively translucent materials, such as low basis weightnonwovens, the resulting laminate web 10 resembles a sequined fabric.

[0124] The use of rather brittle, or relatively still materials can beused as a central layer 30 with beneficial results when the laminate webis incrementally stretched as described herein. For example, thinceramic materials having a relatively high stiffness can be used ascentral layer 30 in a laminate web 10 that is relatively highly flexiblein at least one direction, depending on the direction of stretch.Therefore, if the web is incrementally stretched in the CD direction,the laminate web will be flexible about an axis parallel with the MDdirection, and vice-versa. If the web is incrementally stretched in bothdirections, then the resulting laminate web 10 will be relatively highlyflexible about two axes, and, depending on the size of the discrete“islands” of central layer produced, approaches the overall flexibilityof the two outer layers.

EXAMPLES

[0125] The following examples are shown in Table 1 as exemplary of theclaimed invention. Because the choice of outer and inner layers andcombinations is virtually infinite, the examples shown are meant to beillustrative of possible structures, and are not meant to be limiting toany particular material or structure. In particular, the examples shownare limited to currently preferred structures comprising nonwoven websas the outer layers.

[0126] In Table 1 various combinations of materials are shown. Thelayers are numbered in order of structural proximity from one outerlayer to the other. Therefore, layer 1 is always an outer layer, and thelast numbered layer is likewise an outer layer.

[0127] For all the samples shown, the calendaring line speed was 100feet per minute, but the line speed is not considered critical to theoperation of the method. The calendaring pressure was 700 psig for allthe samples, but the pressure can be varied as desired as long asbonding is achieved between the outer layers.

[0128] To form apertured embodiments of the samples below, the thermallybonded laminate was processed by the incremental stretching process asdescribed above with reference to FIG. 12. For these samples a “pitch”and depth of engagement (“DOE”) are shown.

[0129] Clopay PE films were obtained from Clopay, Cincinnati, Ohio Thesethin (about 0.001″ thick) films are a soft and deformable polyethylenetype, often used as fluid barrier materials for absorbent products.

[0130] Tredegar elastomeric formed films were obtained from TredegarFilm Products, Terre Haute, Ind. By “formed film” is meant amacroscopically-expanded three-dimensional plastic web comprising acontinuum of capillary networks originating in and extending from onesurface of the web and terminating in the form of apertures in theopposite surface thereof. Such a formed film is disclosed in commonlyassigned U.S. Pat. No. 4,342,314 issued to Radel et al. on Aug. 3, 1982.Elastomeric formed films are an improvement in the aforementioned Radelet al. web as disclosed in the above-mentioned commonly assigned,copending U.S. patent application Ser. No. 08/816,106 entitled TearResistant Porous Extensible Web, filed Mar. 14, 1997 in the name ofCurro et al. Curro '106 discloses elasticized polymeric webs generallyin accordance with the aforementioned Radel et al. Patent that may beproduced from elastomeric materials known in the art, and may belaminates of polymeric materials. Laminates of this type can be preparedby coextrusion of elastomeric materials and less elastic skin layers andmay be used in the body hugging portions of absorbent garments, such asthe waistband portions and leg cuffs.

[0131] High internal phase emulsion open cell foam materials can be madegenerally in dance with the teachings of the above mentioned U.S. Pat.Nos. 5,260,345 and U.S. Pat. No. 5,268,224.

[0132] BBA and Corovin/BBA nonwovens were obtained form BBA, Greenville,S.C.

[0133] BOUNTY® paper towels were obtained from The Procter & Gamble Co.,Cincinnati, Ohio.

[0134] REYNOLD'S metal foil products were obtained from Reynold's MetalProducts company.

[0135] 3M products were obtained from 3M, Minneapolis, Minn.

[0136] For the materials shown below, the basis weight is expressed ingrams per square meter (gsm). Low density polyethylene is denoted“LDPE”; polypropylene is denoted as “PP”; and polyethylene is denoted as“PE”. Spunbond is denoted as “SB”. TABLE 1 Examples of Laminate Webs ofthe Present Invention Roller Temp. Anvil/ Pitch/ Exam- Pattern DOE pleNo. Layer 1 Layer 2 Layer 3 Layer 4 Layer 5 (deg. F) (inches) 1 30 gsmLDPE 42 gsm 30 gsm LDPE 250/270 SB nonwoven BOUNTY ® SB nonwoven fromPaper Towel from Corovin/BBA Corovin/BBA 2 30 gsm LDPE 42 gsm 42 gsm 30gsm LDPE 250/270 0.200/ SB nonwoven BOUNTY ® BOUNTY ® SB nonwoven 0.300from Paper Towel Paper Towel from Corovin/BBA Corovin/BBA 3 30 gsm LDPE42 gsm 30 gsm LDPE 250/270 0.060/ SB nonwoven BOUNTY ® SB nonwoven 0.850from Paper Towel from Corovin/BBA Corovin/BBA 4 80/20 (PE/ 23 gsm PE50/50 (PE/ 275/295 PP) 30 gsm film from PP) 30 gsm SB nonwoven Clopay SBnonwoven from BBA from BBA 5 80/20 (PE/ 23 gsm PE 50/50 (PE/ 275/2950.200/ PP) 30 gsm film from PP) 30 gsm 0.300 SB nonwoven Clopay SBnonwoven from BBA from BBA 6 80/20 (PE/ 42 gsm 23 gsm PE 50/50 (PE/275/295 PP) 30 gsm BOUNTY ® film from PP) 30 gsm SB nonwoven Paper TowelClopay SB nonwoven from BBA from BBA 7 80/20 (PE/ 42 gsm 23 gsm PE 50/50(PE/ 275/295 0.200/ PP) 30 gsm BOUNTY ® film from PP) 30 gsm 0.300 SBnonwoven Paper Towel Clopay SB nonwoven from BBA from BBA 8 30 gsm LDPEM77 spray REYNOLDS ® M77 spray 30 gsm LDPE 275/295 0.060/ SB nonwovenadhesive from 65 gsm adhesive from SB nonwoven 0.850 from 3M aluminumfoil 3M from Corovin/BBA approx. 13 approx. 13 Corovin/BBA gsm gsm 9 30gsm LDPE 88 gsm 42 gsm 30 gsm LDPE 250/270 0.200/ SB nonwovenelastomeric BOUNTY ® SB nonwoven 0.300 from formed film Paper Towel fromCorovin/BBA from Tredegar Corovin/BBA 10 30 gsm LDPE Spray hot 62 gsmHigh Spray hot 30 gsm LDPE 250/270 0.200/ SB nonwoven melt adhesiveInternal Phase melt adhesive SB nonwoven 0.300 from from Ato- Emulsionfrom Ato- from Corovin/BBA Findley open cell Findley Corovin/BBA approx.12 foam approx. 12 gsm gsm 11 27 gsm high 42 gsm 60 gsm 295/350 0.060/elongation BOUNTY ® laminate of 0.110 carded PP Paper Towel 80/20 50/50nonwoven (PE/PP) from BBA nonwoven from BBA

[0137] The laminate webs of the present invention may be utilized inmany varied applications. For example, the relatively low cost ofnonwoven, paper and film materials makes the laminates ideally suitedfor disposable articles. The articles discussed herein are exemplary ofthe useful applications for which the laminate of the present inventioncan be used.

[0138]FIG. 17 shows an exemplary embodiment of a disposable diaper 420in a flat configuration (with all elastic induced contraction removed)with portions of the structure being cut-away to more clearly show theconstruction. The portion of the diaper which contacts the wearer facesthe viewer. The diaper is preferably comprises a liquid pervioustopsheet 438; a liquid impervious backsheet 440 joined with the topsheet438; an absorbent core 442 (shown as an apertured laminate of thepresent invention) positioned between the topsheet 338 and the backsheet340; elastic members 344; and tape tab (or mechanical) fasteners 446.The components can be assembled in a variety of well knownconfigurations.

[0139] Liquid pervious topsheet 438 could be made of a laminate web likeExample 4 (unapertured) or Example 5 (apertured) as shown in Table 1.Backsheet 440 could be made of a laminate webs like Example 4, andabsorbent core 442 could be made of a laminate like that of Example 10.Side panels, elastic leg cuffs, and an elastic waist feature can be madeof a laminate web like Example 9. Such a laminate exhibits breathabilityand elasticity, both important in absorbent diapers.

[0140] A preferred diaper configuration for a diaper comprisinglaminates of the present invention is described generally in U.S. Pat.No. 3,860,003, issued Jan. 14, 1975 to Buell. Alternatively preferredconfigurations for disposable diapers are also disclosed in U.S. Pat.Nos. 4,808,178 (Aziz et al.); 4,695,278 (Lawson); 4,816,025 (Foreman);5,151,092 (Buell et al.), all of which are hereby incorporated herein byreference.

[0141] In addition to disposable diapers, various embodiments oflaminates of the present invention are useful for topsheets, backsheets,and cores in other disposable absorbent articles, such as catamenials,panty liners, pull-up diapers, adult incontinence products, and thelike.

[0142] Laminates of the present invention can also be useful as wipes,including wet wipes, shop wipes, facial wipes, and the like. Forexample, Example 3 having an absorbent cellulosic layer as central layer30 would be an excellent wipe for picking up spills and particulatematter that can be captured in the apertures. Likewise, Example 6,having a polyethylene film would be an excellent wipe for harsh jobsrequiring a more durable wipe having extra scrubbing capability. Alaminate of the present invention can be considered a durable orsemi-durable rag or sponge for most purposes.

[0143] Because of the virtually infinite variety of patterns achievableby the method of the present invention, laminates of the presentinvention can find use as components in home furnishings, includingdrapes and upholstery. For example, very lacy, sheer patterns can bemade that are attractive as window coverings. The colors can be variedeasily by varying the component materials, including central layer 30.Higher basis weight materials can be made durable for seat coverings,particularly disposable seat coverings useful in airplanes, buses, andthe like.

[0144] Laminates of the present invention can be useful as disposablebibs. Example 6 in Table 1, for example, having a polyethylene layerwould serve as an effective bib. Even apertured versions, depending onthe size of the apertures can be useful as bibs, as the apertures tendto capture food particles better. After use as a bib the bib can be usedas a wipe to clean up the baby's surroundings after eating.

[0145] Metal-containing webs of the present invention can be used inelectrical applications. For example, Example 8 in Table 1 can be usedin applications requiring electrical shielding having a soft, compliantcarrier material. A laminate similar to Example 8 may find use as acomponent in circuit boards, electrical cabling, and the like.

[0146] A laminate web of the present invention can find use as a filterfor filtering fluids. Air, for example, can be filtered in passing airthrough a suitably designed laminate web of the present invention. Forexample, electrostatic air filters can be made by laminating appropriatedissimilar polymeric nonwoven materials. In one embodiment the filterwould comprise nonwoven materials of suitable material and pore size,and would be provided in an unstretched condition, that is, in alaminate such as that shown with respect to FIGS. 1 and 2. As the filteris used, and the pores become blocked with filtered debris, the tensionplaced on the filter media thereby would cause at least some of the bondsites 50 to open into apertures. Thus, the filter comprises a selfadjusting media that prevents complete blockage of the filter, andavoids overworking of blower motors and the like.

[0147] Other uses for laminates of the present invention include medicaldressings, textured wall coverings, mats and throws, mop heads for dryor wet mops, and geo-textiles.

[0148] While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A non-apertured laminate web comprising: a) afirst web; b) a second web joined to said first web in a face to facerelationship at a plurality of discrete bond sites, the first and secondwebs forming an interior region therebetween; c) a third material beingdisposed between said first and second webs, said third material beingdifferentiated from said first or second web by at least one materialproperty selected from thermal properties, elongation properties,elastic properties, or conductive properties; and d) said third materialbeing apertured in regions coincident said bond sites, such that saidfirst and second webs are joined through said apertures and wherein saidthird material is involved in said discrete bond sites and substantiallyfills said interior region.
 2. The laminate web of claim 1, wherein saidlaminate is joined by bonds in the absence of adhesive.
 3. The laminateweb of claim 1, wherein said bond sites are discrete thermal bondshaving an aspect ratio of at least 3:1.
 4. The laminate web of claim 1,wherein said bond sites are discrete thermal bonds having an aspectratio of at least 10:1.
 5. The laminate web of claim 1, wherein saidfirst or second web comprises a nonwoven.
 6. The laminate web of claim1, wherein said third material comprises cellulosic tissue paper.
 7. Thelaminate web of claim 1, wherein said third material comprises metalfoil.
 8. The laminate web of claim 1, wherein said third material is apolymeric film.
 9. The laminate web of claim 1, wherein said thirdmaterial is open cell foam.
 10. A laminate web having a plurality ofapertures, said laminate web comprising: a) a first extensible webhaving a first elongation to break; b) a second extensible web joined tosaid first extensible web at a plurality of bond sites, said secondextensible web having a second elongation to break; and c) a third webmaterial being disposed between said first and second webs, said thirdweb material having a third elongation to break which is less than bothof said first or second elongations to break.
 11. The laminate web ofclaim 10, wherein said laminate is joined by bonds in the absence ofadhesive.
 12. The laminate web of claim 10, wherein said bond sites arediscrete thermal bonds having an aspect ratio of at least 3:1.
 13. Thelaminate web of claim 10, wherein said bond sites are discrete thermalbonds having an aspect ratio of at least 10:1.
 14. The laminate web ofclaim 10, wherein said first or second extensible web comprises anonwoven.
 15. The laminate web of claim 10, wherein said third webmaterial comprises cellulosic tissue paper.
 16. The laminate web ofclaim 10, wherein said third web material is conductive.
 17. Thelaminate web of claim 10, wherein said third web material comprisesmetal foil.
 18. The laminate web of claim 10, wherein said third webmaterial is an open cell foam.
 19. A laminate web having a plurality ofapertures, said laminate web comprising: a) first and second extensiblewebs being joined at a plurality of discrete bond sites; b) a thirdmaterial disposed between said first and second nonwoven webs; and c)the first and second extensible webs being in fluid communication viathe apertures and having distinct regions being differentiated by atleast one property selected from the group consisting of basis weight,fiber orientation, thickness, and density.
 20. The laminate web of claim19, wherein said laminate is joined by bonds in the absence of adhesive.21. The laminate web of claim 19, wherein said bond sites are discretethermal bonds having an aspect ratio of at least 3:1.
 22. The laminateweb of claim 19, wherein said bond sites are discrete thermal bondshaving an aspect ratio of at least 10:1.
 23. The laminate web of claim19, wherein said first or second extensible web comprises a nonwoven.24. The laminate web of claim 19, wherein said third material comprisescellulosic tissue paper.
 25. The laminate web of claim 19, wherein saidthird material comprises metal foil.
 26. The laminate web of claim 19,wherein said third material is a polymeric film.
 27. The laminate web ofclaim 19, wherein said third material is an open cell foam.
 28. Adisposable absorbent article comprising a laminate web having aplurality of apertures, said laminate web comprising: a) first andsecond extensible webs being joined at a plurality of discrete bondsites; b) a third material disposed between said first and secondnonwoven webs; and c) said first and second extensible webs being influid communication via the apertures and having distinct regions beingdifferentiated by at least one property selected from the groupconsisting of basis weight, fiber orientation, thickness, and density.29. The laminate web of claim 28, wherein said first or secondextensible web comprises a nonwoven.
 30. The laminate web of claim 28,wherein said third material comprises absorbent gelling material.
 31. Amethod for forming a laminate web comprising the steps of: (a) providingfirst and second web materials comprising thermoplastic material; (b)providing at least one third web material; (c) providing a thermal pointbonder having a plurality of protuberances; (d) guiding said third webmaterial between said first and second web materials in a face-to-facelayered relationship to said thermal point bonder; (e) displacing saidthird web material with said protuberances at discrete, spaced apartlocations to form apertures in said third material; and (f) thermallypoint bonding said first and second outer web materials to form bondsites at discrete, spaced apart locations coincident with saidprotuberances, thereby forming a bonded laminate.
 32. The method ofclaim 31, wherein said third web material is provided in an unaperturedcondition.
 33. The method of claim 31, wherein said third web materialis involved in said thermal point bonding about a perimeter of a saidbond sites.
 34. A method for forming an apertured laminate webcomprising the steps of: (a) providing first and second web materialscomprising thermoplastic material; (b) providing at least one third webmaterial; (c) providing a thermal point bonder having a plurality ofprotuberances; (d) providing a stretching means; (e) guiding said thirdweb material between said first and second web materials in aface-to-face layered relationship to said thermal point bonder; (f)displacing said third web material with said protuberances at discrete,spaced apart locations to form apertures in said third material; (g)thermally point bonding said first and second outer web materials atdiscrete, spaced apart locations corresponding to said protuberances,thereby forming a bonded laminate; and (g) stretching said bondedlaminate to form the apertured laminate web.
 35. The method of claim 34,wherein said first and second web materials comprise nonwoven fibers.36. The method of claim 34, wherein said third web material has anelongation to break which is less than both of said first or second webmaterials.
 37. The method of claim 34, wherein said third web materialhas an elongation to break which is greater than both of said first orsecond web materials.
 38. The method of claim 34, wherein said thermalpoint bonder comprises a patterned calendar roller.
 39. The method ofclaim 34, wherein said stretching means comprises incrementalstretching.
 40. The method of claim 34, wherein said protuberances ofsaid thermal point bonder have an aspect ratio of between about 3 and20.
 41. The method of claim 34, wherein said protuberances of saidthermal point bonder have an aspect ratio of 10.